| Maple and Walnut CD Cabinet -- Walls and Trim |
From "Wood Works"
episode WWK-202 |
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In this episode of DIY Wood Works, host David Marks builds a decorative CD cabinet fashioned out of maple and black walnut. As a solution to the problem of CD storage, this vertically designed wood cabinet provides plenty of rack space for a CD collection and is intended to be both functional and visually appealing. It features flared trim as well as a sturdy, angled base and top made of black walnut. The darker walnut accents contrast with the light maple of the cabinet. The piece is adorned with a whimsical accent -- a door-pull made of ebony and carved in the shape of a musical note. The proportions of the case are determined by the size of the rack inserts being used. For this project, plastic commercially made CD racks (figure A) were purchased from a woodworking store. They fit along the inside surfaces of the inner walls (figure B) that attach to the outer cabinet walls and provide the proper spacing for holding CDs stacked horizontally. The sides of the cabinet are butted together (figure C) and joined with biscuits. The project begins with cutting plywood stock to build the sides. Where the edges of those sides are exposed, they'll be covered with strips of maple Materials: Maple and black-walnut stock
Plywood stock
Plastic CD racks (available from woodworking stores)
Table saw
Drum sander
Band saw
Fingerboard
Table router; flush-bearing bit
Biscuit joiner; wood biscuits
Yellow wood-glue
Clamps
Cork blocks
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc. Cabinet Walls Steps:
- The plywood stock for the case is cut on the table saw (figure D), leaving the pieces slightly oversized.
- Next, using fingerboards to hold the stock steady on the band saw, 1/8-inch strips of maple (figure E) are ripped from a piece of solid stock. The thin strips are then rut through the drum sander to eliminate any rough spots left by the saw-blade.
- The thin strips are then ready to be glued to the plywood using yellow wood glue. Elevate the plywood on shims, and glue the strips in place (figure F), overhanging the top and bottom surfaces of the plywood just a bit.
- The pieces can then be clamped together (with pieces edge-to-edge, as shown to use fewer clamps) to hold them securely as the glue dries (figure G).
- After the glue has dried, clean edges along the top and bottom are created by trimming away the excess at the router table, using a flush-bearing bit (figure H).
- With the plywood stock banded with maple, the stock is cut to size, using the table saw, for the elements of the cabinet (figure I).
- A biscuit jointer is used to cut slots for the joinery of the maple/plywood case (figure J and K). Slots are cut in the side, top and bottom pieces.
- One side of the cabinet is cut slightly wider than the other (figure L) to accommodate the thickness of the hinged door that will be mounted later.
- With all of the slots cut, the cabinet is dry-fit to make sure that all of the pieces fit snugly. For glue-up, the assembly is set on wood blocks to elevate it and provide better access for clamping (figure M).
- With the slots cut, and the dry-fit complete, glue-up can begin. With the large number of slots in the biscuit joinery, the application of glue is simplified by the use of a biscuit-shaped applicator (figure N).
- Once all the pieces have been glued, and assembly of the cabinet is complete, the assembly is clamped securely (figure O) as the glue dries. Cork-blocks on the clamps prevent the wood from being marred. The cork-blocks were taped to the clamps in advance, saving work time as the glue begins to harden.
- As the glue dries on the cabinet, work can begin on the inner walls. Plywood stock is cut to size and milled up, and maple trim is added to the leading edge.
- The plastic racks can then be installed on the inner walls. The racks are positioned (figure P) to mark for pre-drilled holes.
- Once the marks are made, the holes can be drilled.
- Tip: To line up the holes accurately, use a self-centering drill bit ( figure Q).
- Holes are also drilled in the sides for the pins that will hold the maple top shelf in place.
- Once all of the holes have been drilled, the inner walls are glued into the center section and clamped secure while the glue dries. A combination of spring and screw-clamps is used (figure R) to provide adequate pressure for a solid bond between the pieces.
Walnut Trim While the maple cabinet is drying, work can begin on the corner trim. Black-walnut stock, that's 1-1/2 square, is used to create the trim pieces. The dark walnut trim provides the attractive, contrasting border for the cabinet (figure S). The trim pieces are flared from the top to bottom to supply some visual weight. - To make the trim, a rabbet is cut along the inside corner of the black walnut stock to wrap around the outside corners of the CD cabinet, covering the plywood edge. The blade on the table saw is set to 7/8-inch, and two passes are made to cut the rabbet in each of the trim pieces (figure T).
- After the rabbet has been cut in the trim piece, a tapering jig is used on the table saw to taper one outside face on the trim. The stock is then rotated in the jig to cut a matching taper on the other outside face.
- After the outside faces have been tapered, the stock is turned to taper the inside surfaces as well. Since the outside faces have been tapered, the flat references have been removed. To compensate for that, a shim is inserted in the tapering jig to make the cuts tapering the inside faces (figure U). As before, cut the first inside face, then rotate the stock to cut the second inside face.
- Once the rabbets have been cut in the trim, and the pieces have been tapered, the trim pieces are glued to the corners of the case using yellow glue.
- Once they have been glued, the assembly is clamped securely until the glue dries (figure V). Again, cork blocks are used to protect the wood from clamp damage.
In the segment that follows, the black-walnut angled base for the cabinet is made.Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
The Complete Woodworker's Companion
Author: Roger Holmes
Publisher: Watson-Guptill
ISBN: 0823008665
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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